Extruded support members for facilitating access to a vehicle and related methods

ABSTRACT

Support devices and their components are disclosed, including an optional lighting element mountable on the support device for emitting light. The support device facilitates access to a vehicle and includes an elongate extruded support member, brackets for mounting the elongate extruded support member to a vehicle, and a step affixed to the elongate extruded support member. A mount can be provided and coupled to the lighting element and to the step to secure the lighting element to the step when the lighting element is incorporated.

FIELD OF ART

The field of the invention relates to systems and methods forfacilitating entry and exit from a vehicle.

BACKGROUND

Vehicles provide transportation for people and objects over distances.While many vehicles are low to the ground or have otherwise easilyaccessible passenger compartments, some do not and entry and exit maypresent a challenge. Typical examples of vehicles with more difficultaccess to passenger compartments include pickup trucks, sport-utilityvehicles, off-road vehicles, “raised” or “lifted” automobiles andothers. In these types of vehicles the passenger compartment orcompartments may be located at a height which makes entry and exitchallenging for children, the elderly or infirm and even normalabled-body adults.

Various solutions are available for addressing the problem of easyaccess to a passenger's compartment including the use of running boards,attached step-ladders, handles to assist a passenger in pullingthemselves up and others. However, existing solutions still have manydrawbacks. These drawbacks include twisting from applied weight,capturing dirt and other debris, inability to adjust the mountingposition, and difficulty or impossibility of modification or removal.

SUMMARY

Support devices and lighting elements usable with support devices aredisclosed. The lighting elements can emit light along a singledirection, such as a unidirectional light, and can be coupled withadditional lighting elements to emit light along two or more directions,such as up and down relative to a horizontal plane. The lightingelements may be installed on a running board of a vehicle, on anextruded support member, on one or more steps connected to the extrudedsupport member, or combinations thereof.

Various power arrangements and control options are available forpowering the controlling the lighting elements, which can comprise LEDstrips comprising a plurality of individual LEDs per unit length. Thestrips can be mounted to a flexible fiber board or to a rigid housing orboard, such as an aluminum housing.

Aspects of the present disclosure includes a support device forfacilitating access to vehicles. The support device can comprise: anelongate extruded support member comprising a length; brackets formounting the elongate extruded support member to a vehicle; a stepaffixed to the elongate extruded support member, wherein the stepcomprising a landing surface comprising holes allowing light to passtherethrough; a lighting element mounted below the landing surface andconfigured to emit light through the holes in the landing surface; and amount coupled to the lighting element and to the step to secure thelighting element to the step.

The support device wherein the lighting element can be powered by abattery located in an underside cavity of the step.

The support device wherein the brackets can be repositionable along thelength of the elongate extruded support member.

The support device wherein the step can be a first step and the supportdevice can further comprise a second step affixed to the elongateextruded support member and spaced from the first step.

The support device wherein the mount can comprise a ring defining afitted hole for securing the lighting element.

The support device can further comprise a first support extending fromthe ring and a second support extending from the ring and spaced fromthe first support.

The support device wherein the lighting element can emit light outthrough the holes and through an underside opening opposite the landingsurface.

The support device wherein the lighting element can be connected to acontroller of a vehicle and operable by a switch located inside thevehicle.

Aspects of the present disclosure further include a support device forfacilitating access to vehicles comprising: an elongate extruded supportmember comprising a length; brackets for mounting the elongate extrudedsupport member to a vehicle; a step affixed to the elongate extrudedsupport member, wherein the step comprising a landing surface comprisingholes allowing light to pass therethrough; a lighting element mountedbelow the landing surface and configured to emit light through the holesin the landing surface and to a ground surface away from the landingsurface; and wherein the lighting element comprises a unidirectional LEDstrip comprising a plurality of LEDs.

The support device wherein the step can comprise a sub-assemblycomprising a tubular lower step bar and two attachment brackets andwherein an angle is provided between each of the two attachment bracketsand the tubular lower step bar.

The support device wherein the step can comprise a step bar attached tothe tubular lower step bar; and wherein the step bar can comprise thelanding surface comprising holes.

The support device wherein the lighting element can be located in atransparent housing and filled with a transparent epoxy resin.

The support device wherein the lighting element can comprise a first rowof light and wherein a second row of light can be located in adjacentcontact with the first row of light.

The support device wherein the two row of lights can be located in atransparent housing and mounted under the landing surface.

The support device wherein the extruded support member can benon-circular and wherein the two attachment brackets can be welded tothe extruded support member.

A further aspect of the present disclosure includes a method formanufacturing a support device for use to access a vehicle. The methodcan comprise: obtaining an extruded support member comprising a length;attaching brackets to the extruded support member so that the extrudedsupport member can attach to a vehicle through the brackets; securing astep to the elongate extruded support member, wherein the step comprisesa landing surface comprising holes to allow light to pass therethrough;mounting a lighting element below the landing surface so that when thelighting element is activated, light is illuminated through the holes inthe landing surface and to a ground surface away from the landingsurface; and wherein the lighting element comprises a unidirectional LEDstrip comprising a plurality of LEDs.

The method wherein the step can comprise a step sub-assembly comprisinga tubular section with two bends forming a lower step bar and twoattachment flanges.

The method wherein the extruded support member can be non-circular incross-section and wherein the two attachment flanges can be welded tothe extruded support member.

A still further aspect of the present disclosure is a support device forfacilitating access to vehicles comprising: an elongate hollow supportmember comprising a length and having a landing surface; bracketsattached to the hollow support member and to a vehicle; a lightingelement mounted below the landing surface and configured to emit lightin a direction opposite the landing surface or through holes provided inthe landing surface; and a mount or bracket coupling the lightingelement to the elongate hollow support member.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present device, system,and method will become appreciated as the same becomes better understoodwith reference to the specification, claims and appended drawingswherein:

FIG. 1 shows a support device comprising an extruded support member withsteps according to an embodiment of the present invention.

FIG. 2 is an example view of an extruded support member with stepsattached to a pickup truck according to an embodiment of the presentinvention.

FIG. 3 is an example view of a step according to an embodiment of thepresent invention.

FIG. 4 is an example exploded view of a support device comprising anextruded support member with steps according to an embodiment of thepresent invention.

FIG. 5 is an example embodiment of a step with a lighting element andmounting for the lighting element.

FIG. 6 is an example embodiment of a mount usable to mount a lightingelement.

FIG. 7 is an example embodiment of a step plate or step bar.

FIGS. 7A and 7B are schematic front elevation and cross-sectional sideview of an alternative step provided in accordance with aspects of thepresent disclosure.

FIG. 7C is a schematic process diagram showing a lighting elementconnected to one or more controllers.

FIGS. 7D and 7E show two different versions of a light assembly.

FIGS. 7F-7I show four different versions of a lighting element assembly.

FIG. 8 is an example embodiment of a step mounted to an extruded supportmember.

FIG. 8A is a schematic cross-sectional side view of an alternative stephaving a lighting element connected thereto.

FIG. 9 is an example embodiment of a step mounted to an extruded supportmember.

FIG. 10 is an example embodiment of an extruded support member.

FIG. 11 is an example embodiment of an extruded support member.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of the presently preferredembodiments of support members provided in accordance with aspects ofthe present devices, systems, and methods and is not intended torepresent the only forms in which the present devices, systems, andmethods may be constructed or utilized. The description sets forth thefeatures and the steps for constructing and using the embodiments of thepresent devices, systems, and methods in connection with the illustratedembodiments. It is to be understood, however, that the same orequivalent functions and structures may be accomplished by differentembodiments that are also intended to be encompassed within the spiritand scope of the present disclosure. As denoted elsewhere herein, likeelement numbers are intended to indicate like or similar elements orfeatures.

FIG. 1 is an exemplary perspective view of a support device 100 providedin accordance with aspects of the present disclosure. In the exampleembodiment, the support device 100 is provided with an extruded supportmember 102 comprising one or more steps 104 and one or more brackets 106for attaching the support device 100 to a vehicle 10 (FIG. 2), such asto a pickup truck, a van or a sport utility vehicle (SUV), to name a fewnon-limiting examples. The number of steps 104 incorporated with thesupport device 100 can depend on the number of doors the support deviceis mounted to, such as a two door truck or a four door SUV.

The brackets 106, which can total three, more than three or less thanthree, are shaped metals attached to the elongated extruded supportmember 102, such as being welded thereto or secured thereto usingfastening means. The brackets 106 can each have a base 108 and a flangeor mounting flange 110, which can have one or more mounting holes toreceive fasteners for fastening the support device 100 to a vehicle. Theflanges 110 of the brackets 106 can be similar or different in size,shape, and/or contour so as to comport to the shape of the vehicle to bemounted therewith. In some examples, each bracket 106 can have twoflanges 110 and resembles a Z-shaped structure, as further discussedbelow with reference to FIG. 4.

The steps 104 can each comprise a step bar 112 and two attachmentflanges 114. As shown, the attachment flanges 114 can be welded to thestep bar 112 and to the extruded support member 102. In other examples,the attachment flanges 114 are fastened to the step bar 112 and thesupport member 102. The step bar 112 can have the same shape orstructure as the support member 102 or different, such as having asmaller cross-section or a different shaped cross-section. As furtherdiscussed below, the step bar 112 can be hollow with an upper bottomcavity for optionally mounting accessory devices, such as one or morelighting elements. The two flanges 114 can embody flat plates withoptional openings for aesthetic appeal and to decrease drag. The twoflanges 114 can be angled or be flat or straight as necessary to secureto both the step bar 112 and the support member 102.

A cap or end cap 120 can be mounted to each end of the support member102. The cap 120 can prevent dust and other build ups from entering theinterior of the support member 102. As shown, the cap 120 eachfrictionally engages the exterior and/or interior of the support member102 to secure therewith. In some examples, detents, fasteners, such asset screws, or other securement means may be used to more securelyattach the caps to each end of the support member. The cap can be madefrom plastic or cast metal.

In an exemplary embodiment, the extruded support member 102 has a pseudooval shape or a pseudo inverse trapezoid profile (also shown in FIG. 4)with a hollow interior. In other examples, the support member 102 mayhave other cross-sectional shapes, including an elongated oval shape, anirregular shape, etc. so long as an upper surface of the structure foruse to step on has a stepped surface with a sufficient surface area tosupport a user's foot or feet. The shape of the support member 102 maysimply be referred to as a support profile for simplicity. The supportprofile of the extruded support member 102 includes a top landingsurface 122 and a side support surface 124. In an example, the sidesupport surface 124 embodies a flat angled surface giving the steps 104a relatively larger mounting surface (larger vertical cross section—theamount of material measured vertically) to mount the attachment flanges114. As a result, this stable support provided by the flat angledsurface increases safety because there is less chance that a passengerattempting to enter a vehicle may be thrown or slip off the device dueto the device twisting than in other configurations, thereby reducingthe likelihood of injury from falling.

Similarly, reliability of use of the support device 100 is increasedwhen there is less chance of twisting such that a passenger will be ableto enter the vehicle successfully without falling. Thus, an aspect ofthe present disclosure is understood to include a support device 100having a support member 102 with a top landing surface 122 of sufficientlanding surface area to comfortably and safely support a user whentraversing the vehicle in combination with a side support surface 124having a sufficiently large vertical cross section to increase themounting area or surface for one or more steps 104. Additionally,overall performance of the device 100 for its intended purpose isincreased. In some embodiments, the extruded support member 102 may havea curved or arced upper surface 124. In some embodiments the uppersurface or top landing surface 124 of the extruded support member 102may be intended as a step. In yet other examples, surface features maybe provided on the top landing surface 124 to increase grip-ability as asurface for stepping.

In an exemplary embodiment, the extruded support member 102 is craftedof extruded aluminum with other materials contemplated. Extrusion is aprocess by which objects may be created that have a consistent crosssectional profile throughout. Typically extrusion is achieved by drawingor pushing a material through a die having the desired cross-section.Use of extrusion, especially extruded aluminum, allows for the creationof more complex cross-sectional profiles than many other manufacturingtechniques. For example, steel running boards may have a limited numberof designs such as round, square and rectangular while a device createdusing extrusion has many additional and more complex alternatives. Instill other examples, extensions may be added, such as fastened, welded,or combinations thereof, to the extruded body to form even more exampleshapes. For example, additional step plates may be added to the regionsor areas of the support member 102 to be stepped on to increase surfacearea and possibly texture to enhance gripping and friction. For example,this allows for a simple generic under support member to be used and fora final upper support area to be attached thereto for functionality andappeal. The extruded support member 102 may be hollow or semi-hollow invarious embodiments. For example, ribs may be added or provided in theinterior to increase the structural integrity of the support member. Insome embodiments, the extruded support member 102 may be made ofextruded aluminum or reinforced composite material. Engineered plastic,such as PEEK, is also contemplated and is known to be rigid and strong.The extruded support member 102 is described further with regard toFIGS. 10-11 below.

Also shown in FIG. 1 are end-caps 120, which seal the ends of theextruded member 102. Sealing may help to prevent dirt, dust, mud, water,oil and other debris and substances from entering and becoming trappedin the interior of extruded member 102 in embodiments where the extrudedmember is hollow or semi-hollow. Depending on the debris or substance,hidden corrosion of the interior of the extruded member can be preventedby using the end-caps 120. In some embodiments, the end caps 120 may besecured to the extruded support member using one or more securing means.Securing means may include welds, crimps, solders, tapes, glues,epoxies, cements, other adhesives, clips, clasps, screws or othersecuring means.

In some examples, the support device 100 may be practiced with just theextruded support member 102, without the steps 104. Thus, as discussedfurther below with reference to FIG. 2, when mounted to a vehicle, auser or a passenger can step directly onto the extruded support member102 to gain access to the vehicle since one or both steps can be omittedin the alternative embodiment. The support device 100, without the steps104, resembles a running board on a typical SUV or truck.

With reference to FIG. 4, several brackets 106, among others things, areshown. The brackets 106 serve as means for securing the extruded supportmember 102 to a vehicle 10 (FIG. 2). In an exemplary embodiment, twodifferent types of brackets 106, 106 a are shown. For example, one ofthe brackets 106 a may have two different mounting flanges 110 extendingfrom a base 108 while other brackets 106 may each have two similarmounting flanges 110. Different brackets 106 and different flanges 110may be incorporated depending on the needs, such as depending ondifferent vehicle types requiring different mounting arrangements andconfigurations, to attach the support device 100 to the vehicle. Forexample, one bracket 106 may have a longer base 108 than other bracketsor different flanges 110 with different mounting holes due to theparticular configuration of the vehicle. In other embodiments, allbrackets 106 may be identical, all brackets may be different, or amixture of brackets may be used. The type of brackets 106 used may beapplication specific such that one make and model of vehicle may requirea particular type, length, or size of bracket in order to provideadequate clearance from the vehicle for the device. Bracket arm lengthor base 108 as well as the lengths of the flange 110 may also bedifferent in various embodiments in order to facilitate assembly andpassenger compartment access. In an exemplary embodiment, the flanges110 of the brackets 106 are shown with two holes each, operable toreceive screws, nails or other fasteners. In other embodiments, theflanges 110 of the brackets may be fitted with threaded holes, clips,clamps, clasps, bolts and/or other securing means. The flanges 110 maybe placed on the support member 102 in compatible locations withreceivers, guides or other equipped parts located on a vehicle body ininstallation locations and configurations operable to support thesupport device 100 and loads placed on the device 100. Locations forinstallation on a vehicle may include body panels, chassis, frame,bumpers and other locations. In some examples, the locations of thebrackets 106 on the support member 102 may be adjustable, such asslidable or positionable along the length of the support member 102, toenable fine tuning of the various mounts or mount locations between thesupport device 100 and the vehicle to facilitate installation.

The brackets 106 can attach to a vehicle's underside 130 (FIG. 2) toprovide mounting support for the extruded support member 102. In someembodiments, brackets 106 may be attached to a side 132 of a vehicle 10,such as to the side of the lower frame below the doors, to providemounting support for the extruded support member 102. In someembodiments, brackets 106 may be attached to both a vehicle underside130 and side 132 to provide mounting support for the extruded supportmember 102. In an exemplary embodiment, brackets 106 (FIG. 1) are shownas nearly evenly spaced along the length of the extruded support member102. In some embodiments, brackets 106 may not be located so evenlyspaced and may be closer to one end of the extruded support member. Inthe example embodiment shown, brackets 106 are mounted to the undersideof the extruded member 102. In various other embodiments, brackets 106may be mounted to the side, top or other interior or exterior surface ofthe extruded member 102. In some examples, the support member 102 caninclude a groove along a length thereof and the 106 brackets can eachincorporate a tongue for engaging the groove in a tongue-and-groovearrangement. This allows the brackets to be adjusted along the length ofthe support member 102. Fasteners and fastening plates or washers may beused to secure the brackets to the support member.

While the support device 100 of FIG. 1 shows three brackets 106, itshould be understood that fewer or additional brackets may be used invarious embodiments. Additionally, brackets 106 may be oriented orarranged differently. While the example embodiment shows brackets 106with a straight bar configuration extending perpendicular to thelongitudinal axis of the extruded support member 102, in otherembodiments some or all brackets may have different structural shapessuch as “I”, “Y”, “V”, “X”, “T” frame or others. Some or all brackets106 may also extend at angles other than perpendicular to thelongitudinal axis of the extruded support member 102. Other reinforcingmembers may also be provided between brackets, across brackets, throughbrackets, etc. in order to provide additional structural integrity.

With reference again to FIG. 2 in addition to FIG. 1, an extrudedsupport member 100 with attached steps 104 is shown in an operationalconfiguration attached to a pickup truck 10, which can alternatively bea different type of vehicle, such as an SUV or a van. In the exampleembodiment, the extruded support member 102 is mounted on the pickuptruck using brackets (hidden from view) on the vehicle underside 130. Inthe example embodiment, the extruded support member 102 is mounted suchthat it runs parallel to the side 132 of the vehicle body 140 and islocated partially beyond the side wall or side panel 142 of the vehicle10. In this configuration, the steps 104 are located beyond the sidewall 142 of the vehicle 10. For example, the edge of the step bar 112 ofeach step closest to the vehicle 10 can extend laterally of the sidewall 142 such that the steps 104 are completely beyond the side wall ofthe vehicle. In some embodiments, the extruded support member 102 may belocated completely underneath 130 the vehicle body 140 or completelybeyond the side wall 142 of the vehicle 10. Additionally, in someembodiments the extruded support member 102 may include mechanisms whichallow for adjustment based on user needs. For instance, in somecontemplated embodiments, the extruded member 102 may be swung out froma stored configuration under the body of the vehicle to an operableconfiguration outside the vehicle footprint and locked into place foruse by various mechanisms. Such mechanisms may be manually manipulated,automatically manipulated, or semi-automatically manipulated. A supportdevice 100 may be mounted on each side of the vehicle 10. Additionalsupport devices 100 may be mounted to the front and/or the rear of thevehicle, such as to allow access to the vehicle's engine or thevehicle's truck bed.

While the example embodiment shows the extruded support member 102extending from near one wheel well 146 to another wheel well 146, itshould be understood that extruded support members 102 in variousembodiments of the present disclosure may be much shorter or may belonger and mounted such that they extend to an area outside the wheels148.

Although the two steps 104 appear identical in the embodiment shown,they are not identical in every embodiments of the invention andadditional or fewer steps may be provided as necessary. Also, in someembodiments, a step 104 mounted directly to the extruded member 102 mayhave one or more steps 104 mounted below it, such that it has a ladderor step ladder configuration.

Turning now to FIG. 3, a blown up view of an exemplary embodiment of astep 104 is shown in accordance with the present invention. In theexample embodiment, a step bar 112 is shown along with two suspensionarms or attachment flanges 114. As shown in FIGS. 1-2 and 4, thesuspension arms or attachment flanges 114 attach to the extruded supportmember 102 and provide support to the step bar 112. In otherembodiments, a single or three or more suspension arms or attachmentflanges 114 may be used to provide support for the step bar 112. In theexample embodiment, the attachment flanges 114 are shown with cutoutholes 150. This serves to reduce wind resistance when the vehicle is inmotion, to reduce debris collection and to reduce the weight of thestep. In some examples, the shape of the cutout holes 150 on eachattachment flange 114 can be the same or different. In a particularexample, a customer may custom order the shape of the cutout holes inaccordance with his or her liking. For example, the cutout holes canhave letter shapes, number shapes, geometrical shapes, and combinationsthereof so that the customer can request to have his or her name formedas cut-outs or etched. Additionally, the suspension arms or attachmentflanges 114 are generally flat in order to facilitate more efficientmanufacturing and provide an important surface for embellishment usingcutouts, badges, paint, or other method. In some embodiments, suspensionarms 114 may be planar while in other embodiments suspension arms mayhave bends, curves, or other features. In the exemplary embodimentshown, the suspension arms 114 and step bars 112 are welded togetheralthough in other embodiments other connection means may be used, suchas snaps, clasps, or others. Suspension arms 114 in some embodiments canbe solid structures with no holes. While the exemplary embodiment inFIG. 2 shows suspension arms 114 mounted at roughly a forty-five degreeangle between a ground surface and its perpendicular, it should beunderstood that the suspension arms 114 can be mounted at differentangles in various embodiments. The suspension arms 114 can have auniform thickness or variable thickness in various embodiments.

With further reference to FIG. 3, the step bar 112 can have a generallyplanar landing surface 152 for an upper surface and a back angled frontedge 154 for added structural strength to the step design and tosimplify manufacturing. The angled front edge 154 can be a solidstructure or can have holes in different embodiments. In the exemplaryembodiment, the landing surface 152 of the step bar 112 has holes 154,which allow dirt, sand, mud, water and other materials and substances topass through without collecting on the steps. In some embodiments, theholes 154 are spread in a uniform pattern or array while in otherembodiments the holes 154 may be created in a semi-regular or irregularpattern. In the example embodiment shown, the holes 154 are circular inshape. In some embodiments, the holes 154 may be square, rectangular,half-moon shaped, crescent shaped, oval shaped, triangular, or othershapes. The holes 154 in different locations of the base may bedifferent shapes as well, such as triangular along the edges with squareshaped along the interior. The holes 154 and the pattern in which theyare arranged can provide traction advantages over a solid, uniformsurface. In some embodiments, part or all of the circumference orperimeter of some or all of the holes 154 may be raised as bumps toincrease surface friction for stepping. Alternatively or additionally,other bumps, grooves or irregular surfaces may be provided in order toprovide traction for passengers stepping up into a passengercompartment. Friction pads may alternatively or additionally be appliedto the landing surface 152 for increased traction.

In an exemplary embodiment, steps are permanently attached to theextruded support member 102, such as by welding. In other embodiments,the steps 104 can be removable. In some embodiments (such as that shownin FIG. 8), mountable screws and nuts can provide attachment between thesteps and the extruded support member 102. In some embodiments, latches,locks, levers and other mechanisms can be used to secure the steps 104to the extruded support member 102.

Turning now to FIG. 5, an exemplary embodiment of a step 104 is shownfrom a back and underside perspective. In the example embodiment, alighting element 160 is shown. In particular, the lighting element 160is shown attached to the step bar 112 of the step 104. The lightingelement 160 can be tubular, a bar, a strip or other configurations asappropriate. The lighting element 160 can include one or more lights toilluminate ground surfaces below the step. The lighting element 160 caninclude two or more light sub-assemblies 162 configured to illuminateground surfaces below the step as well as through openings, holes, oretched surfaces to shine through the step to emit up, such as oppositethe ground surfaces. Lights included in the lighting element 160 can belight emitting diodes (LEDs), florescent, or other light sources. Forexample, the lighting element 160 can embody a unidirectional lightstrip comprising a plurality of LEDs mounted on a flexible or a rigidfiber board. In other embodiments, the LEDs can be mounted on one ormore aluminum boards. In embodiments with multiple lights, light colorcan be uniform or can include numerous colors. A single LED can alsochange colors without using multiple separate light sources to generatedifferent colors, such as an RGB capable LED. The lighting element 160can be configured to create patterns on illuminated surfaces, such asvehicle manufacturer names or insignias, other signs, or various othershapes or patterns.

In embodiments where the step bar 112 has holes 154 (FIG. 3) in itssurface, the lighting element 160 can provide illumination to at leastportions of the interior surfaces of the holes and through the holes toilluminate upwardly opposite the ground, and optionally also downwardlyonto the ground or onto ground surfaces. The lighting element 160 can besupported by lighting support structures 164, such as mounting brackets.In some embodiments, different lighting support structures 164 can beused in complementary or replacement fashion to support and maintain thelighting element 160 in position.

The lighting element 160 can be powered by different power sources indifferent embodiments. In some embodiments, the lighting element 160 canbe powered by independent batteries located adjacent or near thelighting element, such as a battery box or compartment located in theunderside cavity 182 of the step bar 112 (FIG. 7). In other examples,the lighting element 160 may be wired such that it receives power fromthe vehicle electrical system. When independent batteries are used,photovoltaic recharging systems including all necessary components maybe incorporated to charge the batteries.

The lighting element 160 can be operated by various different mechanismsor controllers. With reference to FIG. 7C, in some embodiments, thelighting element 160 can be wired to the light control system 280 of thevehicle to be controlled and powered thereby. Thus, the lighting element160 can be turned on when a vehicle door is unlocked and/or opened.Similarly, the lighting element can be turned off when an open vehicledoor is closed. The lighting element 160 can be turned on and/or off byone or more switches or buttons wired into the electrical system of thevehicle and mounted in the passenger compartment. Alternatively oraddition thereto, switches or buttons to operate the lighting element160 can be mounted on the exterior of the passenger compartment and/orelsewhere on the vehicle, such as to the interior of the vehicle or thepassenger compartment so that the lighting element 160 can be manuallyor wirelessly activated to illuminate or not illuminate. In someembodiments, the lighting element switches or buttons for activating thelighting element 160 can be located on the step 104 so that they can beoperated manually by engaging and/or disengaging them with a foot, hand,finger, or other appendage. In other embodiments, a wireless sensor canbe mounted on the step and can detect a motion, such as from a foot,which can then turn on the lighting element 160. The lighting element160 can be turned off by a timer, when the vehicle door is opened andthen closed, when the vehicle cabin light is turned off, when thevehicle is set to drive, when manually turned off, or combinationsthereof. With reference again to FIG. 7C, in some embodiments, thelighting element 160 can be coupled to a separate controller 282, apartfrom the vehicle's controller 280, so that it can be operated remotelyby pressing a button on a remote controller, which sends an operationsignal to a communications receiver on the separate controller 282 whichrelays the signal to an operative microcontroller and/or microprocessorwith internal processing and a connected memory storing program code orlogic for operating at least the lighting element 160. Themicrocontroller and/or microprocessor on the separate controller 282 isoperable to change the state of the lighting element 160 using theprogram code or logic such that the lighting element can turn on, turnoff, flash, dim, brighten, and/or any number of numerous otherillumination patterns. In some embodiments, controllers 280 or 282 forlighting elements 160 described herein can be programmed to turn thelighting elements on only when the vehicle is in “park” and/orcompletely stopped, while in other embodiments lighting elements can beon any time the vehicle is on. In certain conditions, such as when usedin off road conditions, the lighting elements 160 can be turned on whenthe vehicle is not on, such as remotely to allow passengers and driversto see the vehicle and surrounding areas as they approach the vehicleunder dark conditions. Optionally, dimmers may be included andcontrollable by the controllers to vary the light intensity or lightoutput.

With reference now to FIG. 7D, a lighting element 160 in the form of aunidirectional light strip 290 comprising a plurality of LEDs 292mounted on a flexible board 294 is shown, which is also known as adirectional LED strip or a surface mounted device (SMD) LEDs. Thelighting element 160 is mounted to a rigid housing 296, such an aluminumhousing having a recessed section for accommodating the LED strip, andterminated with a connector 294 for connecting to a companion connector,which is connected to a controller and a power supply. The lightassembly 295 with rigid housing 296 and connector 296 may be used withor without further encasement, as further discussed below. In oneexample, the light strip of the lighting element 160 comprises 60individual LEDs per 1 meter length for bright or high lumenapplications. In other examples, the light strip comprises 30 LEDs per 1meter length for a lower or ambient lighting application. When used withthe steps 104 of the present disclosure, the lighting should range fromabout 175 lumens to about 500 lumens. In other applications, the lightrating can be higher than 500 lumens. The LEDs 292 have color adjustabletemperatures to control the intensity of the emitted light.

In an example, the LEDs 292 are not encased, which are also known as LEDribbons. However, the LEDs are preferably encased. For example, in theembodiment of FIG. 7F, the flexible light strip 290 of and rigid backing296 of FIG. 7D are placed inside a transparent housing tube 300, whichcan be a clear or transparent hard thermoplastic material such aspolycarbonate. The empty space 302 inside the housing tube 300 is thenback-filled with a clear or transparent casting epoxy resin thus forminga lighting element assembly 161 comprising a dome shaped structure 304around the plurality of LEDs.290. Light can emit through the transparentcasting epoxy when cured. The dome shaped structure 304 can diffuselight emitted by the LEDs 292 to present a dispersed pattern of lightwhen the LEDs are activated.

One or more brackets 310 may be fastened or bonded to the tube housing300 to secure the lighting element assembly 161 to a step 104 of thepresent disclosure. For example, the lighting element assembly 161 maybe secured to the underside cavity 182 of the step bar 112 of FIG. 7 byusing one or both brackets 310 of the lighting element assembly 161 toattach to the interior contact surface 196 of the back angle rear edge158 or the interior contact surface 198 of the back angle front edge154. Alternatively, one or both brackets 310 may be used to secure thelighting element assembly 161 to the underside surface 278 of the stepbar 112. The attachment can be by way of adhesive, Velcro, fasteners orscrews, rivets, clips, or combinations thereof.

FIG. 7E shows the light assembly 295 mounted back to back to form alight assembly comprising at least two emitting rows of LEDs, mounted ona single rigid housing or on two different rigid housings. Like theembodiment of FIG. 7F, the two back-to-back light assembly may be placedinside a tube housing 300 and filled with a clear casting epoxy resin toform a lighting element assembly 161 comprising at least two rows oflight strips or lighting elements 160. As the light strips can beunidirectional, the two light strips can be configured to shine light inopposite directions, such as one in an upward direction and one in adownward reaction. Accordingly, when the lighting element assembly 161of FIG. 7I is used with a step 104 of the present disclosure, one row oflighting element can illuminate the ground surfaces while the other rowof lighting element can illuminate upwards and through the holes oropenings formed on the step bar 112 of the step 104.

FIG. 7G is an alternative lighting element assembly 161 comprising alight assembly 295 comprising a rigid housing 296 and a lighting element160 mounted inside a transparent housing 300. In the present embodiment,the wall surfaces of the housing 300 are generally planar. Thus, when aclear casting epoxy resin is added to the empty space 302 of the housingand cured, a generally constant epoxy layer is formed over each LED 292.The cured epoxy helps to hold the lighting assembly 160 within thehousing 300 but does not otherwise diffract or collimate light anysignificant amount.

FIG. 7H is an alternative lighting element assembly 161 comprising alight assembly 295 comprising a rigid housing 296 and a lighting element160 mounted inside a transparent housing 300. In the present embodiment,the wall surfaces of the housing 300 have a generally concave surface312. Thus, when a clear casting epoxy resin is added to the empty space302 of the housing and cured, a generally convex layer, relative to eachLED 292, is formed over each LED 292. The cured epoxy helps to hold thelighting assembly 160 within the housing 300 and the convex layer actsto generally focus the emitted light.

In some examples, two rows of light assemblies 295 may be placed intothe housing 300 of FIGS. 7G and 7H to form a lighting element assembly161 comprising two rows of lighting elements 160, similar to that ofFIG. 7I but with different housing surfaces. One or more brackets 310may also be included to secure the lighting element assemblies 161 tothe steps of the present disclosure.

In various embodiments of the invention, lighting elements 160 can beinstalled and/or attached in various positions. In some embodiments,specific lighting element position grooves, slots, holes, and otherinstallation locations are created during manufacturing specifically forlighting element positioning. In other embodiments, lighting elements160 may be added, attached, and/or affixed in locations which were notcreated specifically for lighting elements.

Turning to FIG. 6, an example embodiment of a lighting support structureor lighting mounting bracket 164 of FIG. 5 is shown. In the exampleembodiment, the lighting support structure 164 includes a fitted hole166 to snugly fit an end of the lighting element 160 therein. The fittedhole 166 may be formed with a continuous ring or a ring with a gap 168defining the fitted hole 166. In other examples, the shape of the ring168 can be other than round and is sized and shaped to fit the size andshape of the lighting element 160. A first support 170 and secondsupport 172 extend from the ring 168 to engage the underside dimensionsof the step bar 112 (FIG. 5) such that the first and second supports170, 172 will not break free during normal vehicle operation. Thelighting support structure 164 can be made from a thermoplastic, athermoplastic elastometer (TPE), a rubber material, or combinationsthereof. In some embodiments, the lighting support structure 164 is madefrom a metal material. In some embodiments, adhesives can be used tohold the lighting support structure 164 in place. As shown, the secondsupport 172 has a loop 176 defined by a perimeter 174. A contact section180 is provided at a side or edge of the perimeter 174 and configured toabut a corresponding surface in the underside cavity 182 (FIG. 5) of thestep bar 112. Another contact section 184 is provided at the firstsupport 170, which extends from an elongated extension 186. The twocontact sections 180, 184 of the first and second supports 170, 172press against interior surfaces of the underside cavity 182 of the stepbar 112 to form a bias or snap fit arrangement with the underside cavityof the step bar. The lighting support structures 164 can be attached tothe step bar 112 by sliding them through the underside opening 159opposite the landing surface 152.

The snap fit arrangement between the lighting support structure 164 andthe step bar 112 are more clearly shown in the partial perspective viewof FIG. 7, which shows the base bar 112 without the attachment flanges114. As shown, the step bar 112 has a body 190 comprising a landingsurface 152, a back angle front edge 154, and a back angle rear edge158. The back angle front edge 154 can be longer than the back anglerear edge 158 and both taper inwardly towards one another. A firstinternal contact surface 196 and a second internal contact surface 198are provided in the underside cavity 182 of the step bar 112. In someembodiments, the lighting support structure 164 is configured to snapinto place in the underside cavity 182 by wedging the contact section184 of the first support 170 against one of the interior contactsurfaces 196 of the step bar and the contact section 180 of the secondsupport 172 against the other interior contact surface 198 of theunderside cavity 182. Thus, as disclosed, one or more lighting elements160 can be retained under the step plate 112 of the present disclosureusing one or more clips or brackets, adhesives, or other retainingstructures. The lighting element can be selected to emit light in onedirection or multiple directions, including out the holes and out theunderside opening of the step bar.

FIG. 7A is an alternative step 104 provided in accordance with aspectsof the present disclosure. As shown, the step 104 is attached to anextruded support member 102, which is shown in phantom and can embodyany number of support members 102, such as that shown in FIGS. 1 and 4.For example, the step 104 disclosed herein with reference to FIG. 7A maybe usable with a non-circular or non-round shaped extruded supportmember 102. The present step 104 can comprise two attachment brackets orflanges 114, one each at each end of the step bar 112, which can embodythe step bar of FIG. 7. However, in the present embodiment, the twoattachment brackets 114 are not separately attached to the step bar 112but are attached to a lower step bar 112 a (FIG. 7B) forming a step barsub-assembly 270. For example, the two attachment brackets 114 can bepart of a round tubing and the step bar sub-assembly 270 is formed bybending the tubing to form at least two bends 272 to form a step barsub-assembly 270 comprising two attachment brackets 114 and a lower stepbar 112 a. The two tubular attachment brackets 114 and the lower stepbar 112 a can be unitarily formed or separately formed and subsequentlyattached together, such as by welding. When formed by bending, the bends272 can have an angle measured between each respective attachmentbracket and the lower step bar of about 100 degrees to about 150degrees. In other examples, the angles can be different, such as smallerthan 100 degrees or larger than 150 degrees. Each attachment bracket 114may include one or more bends to form a desired fit or shape, such as toform a certain contour or a certain look to fit the extruded supportmember 102. A working edge 276 may be provided at the terminal end 274of the two attachment brackets 114 to fit against the support member 102and attached thereto. For example, each terminal end 274 can be machinedand/or grounded with a fitted surface for mating against a correspondingsurface on the extruded support member 102 to be attached thereto, suchas by welding, fasteners, and/or rivets.

With reference to FIG. 7B and continued reference to FIG. 7A, across-sectional side view of the alternative step taken along line 7B-7Bof FIG. 7A is shown. A step bar 112, such as the step bar of FIG. 7, isshown attached to the lower step bar 112 a of the sub-assembly 270. Likethe step bar 112 of FIG. 7, the present step bar includes holes oropenings on the landing surface 152 so that a lighting element can emitlight through the plurality of holes or openings. For example, theunderside surface 278 of the body 190 can rest on the lower step bar 112a and the back angle front edge 154 of the step bar 112 can straddle theside of the lower step bar 112 a on the side closer to the vehicle.Continuous welds or tack welds may be used to weld the step bar 112 tothe lower step bar 112 a. The back angle rear edge 158 of the step bar112 can extend away from the lower step bar 112 a and the interiorcontact surface 196 can act or function as a mounting surface for alight assembly, as further discussed below. In an alternativeembodiment, the back angle rear edge 158 is in contact with the lowerstep bar 112 a and is welded thereto while the back angle front edge 154is spaced from the lower step bar. When so configured, the interiorcontact surface 198 of the back angle front edge 154 can function as amounting surface for a light assembly or light element.

Turning to FIG. 8, an exemplary embodiment of a step 104 mounted to anextruded support member 102 is shown. In the example embodiment, thestep 104 is mounted to the extruded support member 102 using fasteners210, such as four bolts—two for each attachment flange 114. As shown,screws 210 are inserted into channels 212 formed with the attachmentflanges 114 along the lower surface of the extruded support member 102such that the threaded end of the screw 110 faces outward from theextruded support member 102 and the head of the screw is held in thechannel 212.

With reference to FIG. 8A, the step assembly 104 of FIGS. 7A and 7B isshown with a light element assembly 161 mounted inside the undersidecavity 182 of the step bar 112. As shown, the lighting element assembly161 is attached to the lower step bar 112 a. Alternatively, the lightingelement assembly 161 may be attached to either the back angle front edge154 or the back angle rear edge 158 of the step bar 112. Gaps, spacers,brackets, flanges, clips, and fasteners may be employed to ensureappropriate mounting for the required application, such as to illuminateup, illuminate down, or to illuminate up and down, as previouslydiscussed. The lighting element assembly 161 shown with FIG. 8A may beany of the various light element assemblies discussed elsewhere herein.

FIG. 9 is a blown up view of the support device 100, which more closelyshows the extruded support member 102 and a step 104 having twoattachment flanges attached to the support member. Although not shown,holes may be provided through the surfaces of the step bar 112 and/orthe support member 102.

FIG. 10 shows an end perspective view of an alternative extruded supportmember 102 provided in accordance with aspects of the presentdisclosure. As shown, the alternative support member 102 incorporatesone or more channels 230 that allow any number of bolts and/or screws tobe inserted and adjusted to one of any number of positions. For example,the channels 212 (FIG. 8) on the attachment flange 114 and the channels230 on the support member 102 can receive bolts or screws to enable thestep 104 to be mounted along any desired axial position along the lengthof the alternative support member 102. This design enables fitting ofthe steps to various vehicle designs by enabling the steps to be axiallyre-positioned on the support member 102 to fit or match the vehiclecabin and doors. The channels also allow for installation of gap guardsand/or lighting elements to be mounted to the alternative extrudedsupport member 102. One or more interior ribs 240 are incorporated forincreased structural integrity. Two adjacent interior ribs 240 candefine an interior channel 242 for engaging an end cap 120, such asbrackets that interface between the end cap and the interior channel.

With reference now to FIG. FIG. 11, another alternative support member102 provided in accordance with aspects of the present invention isdisclosed. The present support member is similar to the support membershown in FIG. 10 with a few exceptions. In the present alternativesupport member 102, brackets can be pre-welded to the extruded supportmember 102 to enable quicker installation and reduce weight. Interiorchannels 242 created by interior ribs 240 on the inner surfaces of theextruded support element 102 can be used to provide locations forend-cap 120 (FIG. 4) specific installation brackets.

In some embodiments, the extruded support members 102 discussedelsewhere herein may be mounted in other locations than in proximity tothe passenger compartment. For example, the extruded support membersdisclosed herein may be mounted along the front of a vehicle to provideindividuals with access to the front of a vehicle. This aspect may beuseful for working on an engine which in many embodiments is locatedunder the vehicle hood in the front of the vehicle. In some embodiments,the extruded support members disclosed herein may be mounted along theside of a truck bed. This may provide users with the ability to accessthe contents of the truck bed from the side without having to step up onan uneven tire surface or from a tailgate location. Similarly, on asport utility vehicle, a side mounting may provide access to a roof-rackfor carrying equipment. In some embodiments, the extruded supportmembers disclosed herein may be located at the rear of a vehicle toprovide access to truck beds, trunks or other storage compartments,which may not be easily accessed without use of the extruded supportmembers.

In some embodiments, additional structures, pieces or components may bepresent and may provide additional support, convenience and/or safetyfeatures. Examples may include chains, hinges, springs, cables, ropes,wires, locks, magnets, vacuums, nuts, bolts, buttons, buckles, ties,clamps, pins, flanges, grommets, pegs, rings, rivets, anchors, staples,stitches, straps, ties, zippers, ratchets, latches, levers, pulleys andothers.

With reference again to FIGS. 8 and 10, in some embodiments, thelighting elements 160, light assemblies 295, and lighting elementassemblies 161 discussed elsewhere herein may be mounted directly to theextruded support member 102, in addition to or as an alternative tomounting the lighting fixtures to the steps 104. For example, when steps104 are omitted from a support device 100, the lighting fixtures, suchas the lighting elements 160, light assemblies 295, and/or lightingelement assemblies 161 as described elsewhere herein, can be mounteddirectly to the extruded support member 102. Brackets, clips, and/orfasteners may attach to the channels 230 (FIG. 10) on the extrudedsupport member 102 and then attached or connected to the lightingfixtures. This allows the lighting fixture to emit light upwardly fromthe extruded support member 102 towards the roof of the vehicle and/orin the opposite direction towards the ground surfaces. The lightingfixture may be powered and controlled in accordance with previouslydiscussed options.

In some examples where a support device 100 has both an extruded supportmember 102 and one or more steps 104, the lighting fixture may beinstalled on just the extruded support member 102 for illuminating theone or more steps 104 when activated. Optionally, the one or more steps104 may also be equipped with lighting fixtures, in addition to thesupport member 102, as discussed herein above.

In still other examples, a vehicle's running board, which may comestandard with the vehicle or added as an after-market add-on and canresemble an extruded support member 102 discussed elsewhere herein, maybe used for mounting a lighting fixture of the present disclosure, suchas the lighting elements 160, light assemblies 295, and lighting elementassemblies 161 discussed herein. A running board is typically anelongated body, typically hollow, mounted at or near the bottom of avehicle along a side edge of the vehicle between the front wheel welland the rear wheel well. There are typically two running boards on avehicle, one on each side of the vehicle. A running board may serve as asupport device to help a passenger access a vehicle. For example, apassenger can step onto the elongated body before stepping into thevehicle. In an example, a lighting element 160 or a lighting elementassembly 161 comprising cured epoxy resin, may be mounted to a vehicle'srunning board and energized and controlled in accordance with previouslydiscussed options.

Methods of making and of using the support devices and their componentsare understood to be within the scope of the present disclosure.

Although limited embodiments of support devices and assemblies and theircomponents have been specifically described and illustrated herein, manymodifications and variations will be apparent to those skilled in theart. For example, the various support devices may incorporate custompaint, have different outer contoured shapes, provided with metallicovercoats, etc. Furthermore, it is understood and contemplated thatfeatures specifically discussed for one support device embodiment may beadopted for inclusion with another support device embodiment, providedthe functions are compatible. Accordingly, it is to be understood thatthe support devices and assemblies and their components constructedaccording to principles of the disclosed device, system, and method maybe embodied other than as specifically described herein. The disclosureis also defined in the following claims.

What is claimed is:
 1. A support device for facilitating access tovehicles comprising: an elongate extruded support member comprising abody with a length, two open ends, and a hollow interior; said bodyhaving a non-circular cross-sectional profile with an upper landingsurface and an angled side support surface extending therefrom; bracketscoupled to the elongate extruded support member for mounting theelongate extruded support member to a vehicle; a step affixed to theelongate extruded support member, wherein the step comprises a landingsurface comprising holes allowing light to pass therethrough, a firstend and a second end; a first attachment flange attached to the firstend of the step and a second attachment flange attached to the secondend of the step, each of said first and second attachment flangescomprising an end edge welded to the angled side support surface of theelongate extruded support member; and wherein the step comprises aunderside cavity and an open channel opposite the landing surface. 2.The support device of claim 1, wherein the first attachment flange andthe second attachment flange are generally flat and the generally flatsurface of the first attachment flange contacting the first end and thegenerally flat surface of the second attachment flange contacting thesecond end.
 3. The support device of claim 1, wherein the brackets arerepositionable along the length of the elongate extruded support member.4. The support device of claim 1, wherein the step is a first step andfurther comprising a second step affixed to the elongate extrudedsupport member and spaced from the first step.
 5. The support device ofclaim 1, further comprising interior ribs located in the hollow interiorof the elongate extruded support member.
 6. The support device of claim5, further comprising an end cap secured to at least one of the interiorribs.
 7. The support device of claim 1, further comprising one or morecut-outs formed through the first attachment flange.
 8. The supportdevice of claim 1, wherein the brackets each comprises a base and amounting flange extending from the base, said mounting flange comprisingone or more holes.
 9. A support device for facilitating access tovehicles comprising: an elongate extruded support member comprising abody with a length, two open ends, and a hollow interior; said bodyhaving a non-circular cross-sectional profile with an upper landingsurface and an angled side support surface extending therefrom; bracketscoupled to the elongate extruded support member for mounting theelongate extruded support member to a vehicle; a step extending from theelongate extruded support member, wherein the step comprises a landingsurface comprising holes allowing light to pass therethrough, aunderside cavity, and an open channel opposite the landing surface; afirst attachment flange attached to a first end of the step and a secondattachment flange attached to a second end of the step, said first andsecond attachment flanges are generally flat and the generally flatsurface of the first attachment flange contacting the first end and thegenerally flat surface of the second attachment flange contacting thesecond end; and an end cap attached to each of the open ends of theelongate extruded support member.
 10. The support device of claim 9,wherein the body of the elongate extruded support member has a pseudooval shape or a pseudo inverse trapezoid profile with the angled sidesupport surface extending from a side.
 11. The support device of claim9, wherein the first and second attachment flanges are welded to theangled side support surface.
 12. The support device of claim 9, whereinfirst and second attachment flanges are repositionable on the elongateextruded support member.
 13. The support device of claim 9, furthercomprising one or more cut-outs formed through the first attachmentflange.
 14. The support device of claim 13, further comprising one ormore cut-outs formed through the second attachment flange.
 15. Thesupport device of claim 9, wherein the end caps are secured to the openends by friction, by fasteners, or combinations thereof.
 16. The supportdevice of claim 9, wherein the step is a first step and furthercomprising a second step affixed to the elongate extruded support memberand spaced from the first step.